Knocked-down case inspection and erection method

ABSTRACT

Techniques for corrugate and chipboard knocked-down case inspection and assembly are described herein. In one example, the disclosed techniques include a method to inspect and assemble a knocked-down case. In the example, a measurement of at least one aspect of the knocked-down case is obtained. A difference is determined between the obtained measurement and a standard measurement and/or a range of standard measurements. Programming of a case-handling tool is executed that is based at least in part on the determined difference. In an example, the programming is configured to adjust for and/or compensate for differences between the actual knocked-down case and a knocked-down case that is within a specification. A case-handling tool is operated responsive to the executed programming to at least partially erect the knocked-down case into an erected case.

RELATED APPLICATIONS

This patent application claims the benefit of priority to U.S.provisional patent application Ser. No. 62/782,052, titled “Corrugateand Chipboard Knockdown Inspection System and Method”, filed on 19 Dec.2018, and to U.S. provisional patent application Ser. No. 62/787,144,titled “Corrugate and Chipboard Knockdown Inspection System and Method”,filed on 31 Dec. 2018, both of which are incorporated herein byreference.

BACKGROUND

Case erecting and sealing must be performed to result in a case that iswithin prescribed dimensions. Improved systems are needed to determineif dimensions of case fabrication materials, knocked-down cases, erectedcases, and/or sealed cases are within specified dimensions and/or rangesof dimensions.

BRIEF DESCRIPTION OF THE DRAWINGS

The detailed description is described with reference to the accompanyingfigures. In the figures, the left-most digit(s) of a reference numberidentifies the figure in which the reference number first appears. Thesame numbers are used throughout the drawings to reference like featuresand components. Moreover, the figures are intended to illustrate generalconcepts, and not to indicate required and/or necessary elements.

FIG. 1A shows a first side of an example knocked-down case.

FIG. 1B shows a second side of the example knocked-down case.

FIG. 1C shows an example data acquisition system, which for purposes ofthe example includes an optical scanning apparatus.

FIG. 1D shows an example system to inspect and assemble knocked-downcases.

FIG. 2 shows a robotic arm and end-of-arm tool and example operationwherein a location of a pick-off point on a knocked-down case may beadjusted based at least in part on dimensions of the knocked-down caseand/or differences between dimensions of the knocked-down case andspecifications for the case.

FIG. 3 shows a robotic arm and end-of-arm tool and example operationwherein a location at which a partially erected case is put on aconveyor system or other location is based at least in part ondimensions of the knocked-down case and/or differences betweendimensions of the knocked-down case and specifications for the case.

FIG. 4 shows a conveyor system having side belt drives and exampleoperation wherein width between opposed side belt-drives is based atleast in part on dimensions of the knocked-down case and/or differencesbetween dimensions of the knocked-down case and specifications for thecase.

FIG. 5 shows a magazine with a cassette of knocked-down cases andexample operation wherein a location of a knocked-down case is adjustedbased at least in part on dimensions of the knocked-down case and/ordifferences between dimensions of the knocked-down case andspecifications for the case.

FIG. 6 shows a robotic arm and end-of-arm tool and example operationwherein a path of movement of the arm and tool is based at least in parton dimensions of a knocked-down case and/or differences betweendimensions of the knocked-down case and specifications for the case.

FIG. 7 shows a leading minor flap plow and example operation wherein anelevation of the plow is adjusted based at least in part on dimensionsof a knocked-down case and/or differences between dimensions of theknocked-down case and specifications for the case.

FIG. 8 shows a major flap plow and example operation wherein operatingparameters of the plow are adjusted based at least in part on dimensionsof a knocked-down case and/or differences between dimensions of theknocked-down case and specifications for the case.

FIG. 9 shows a tape head and example operation wherein an elevation orother parameters of the tape head are adjusted based at least in part ondimensions of a knocked-down case and/or differences between dimensionsof the knocked-down case and specifications for the case.

FIG. 10 shows a glue head or glue gun and example operation wherein anelevation or other parameters of the glue head are adjusted based atleast in part on dimensions of a knocked-down case and/or differencesbetween dimensions of the knocked-down case and specifications for thecase.

FIG. 11 a conveyor with flight lugs and example operation wherein aposition or other parameters of one or more flight lugs are adjustedbased at least in part on dimensions of a knocked-down case and/ordifferences between dimensions of the knocked-down case andspecifications for the case.

FIG. 12 shows a trailing minor flap plow and example operation whereinoperating parameter(s) of the plow are adjusted based at least in parton dimensions of a knocked-down case and/or differences betweendimensions of the knocked-down case and specifications for the case.

FIG. 13 shows a glue mandrel and example operation wherein operatingparameters of the mandrel are adjusted based at least in part ondimensions of a knocked-down case and/or differences between dimensionsof the knocked-down case and specifications for the case.

FIG. 14 shows flap spreaders and example operation wherein operatingparameter(s) of the spreaders are adjusted based at least in part ondimensions of a knocked-down case and/or differences between dimensionsof the knocked-down case and specifications for the case.

FIG. 15 shows a robotic arm and end-of-arm tool and example operationwherein a knocked-down case is rejected based at least in part ondimensions of a knocked-down case and/or differences between dimensionsof the knocked-down case and specifications for the case.

FIG. 16 is a flowchart showing a method and example operation of asystem configured to measure, and/or obtain measurement data of, a casewhile in a folded-flat configuration and erect the case based in part onthe measurements.

FIG. 17 is a flowchart showing a method and example operation of asystem configured to measure, and/or obtain measurement data of, a casewhile in a folded-flat configuration and erect the case based in part onthe measurements.

FIG. 18 is a flowchart showing a method and example operation of asystem configured to measure, and/or obtain measurement data of, a casewhile in a folded-flat configuration and erect the case based in part onthe measurements.

FIG. 19 is a flowchart showing a method and example operation of asystem configured to measure, and/or obtain measurement data of, a casewhile in a folded-flat configuration and erect the case based in part onthe measurements.

FIG. 20 is a flowchart showing a method and example operation of asystem configured to measure, and/or obtain measurement data of, a casewhile in a folded-flat configuration and erect the case based in part onthe measurements.

FIG. 21 is a flowchart showing a method and example operation of asystem configured to measure a case while in a folded-flat configurationand erect the case based in part on the measurements.

FIG. 22 is a flowchart showing a method and example operation of asystem configured to measure a case while in a folded-flat configurationand erect the case based in part on the measurements.

FIG. 23 is a flowchart showing a method and example operation of asystem configured to measure a case while in a folded-flat configurationand erect the case based in part on the measurements.

FIG. 24 is a flowchart showing a method and example operation of asystem configured to measure one or more aspects of a case in a stage ofassembly, determine differences between the measurements andspecifications, adjust programming, and operate case-handling tools.

FIG. 25 is a flowchart showing a method and example operation of asystem configured to manufacture knocked-down cases.

DETAILED DESCRIPTION

Overview

The disclosure describes several systems and methods and theirapplications, including techniques for assembling a knocked-down casefrom a folded-flat condition to a fully erected and sealed case.

Example Systems

FIG. 1A shows a first side of an example knocked-down case 10. In theview shown, a major panel 12 is somewhat larger than a minor panel 14,which will result in a rectangular case upon erection of the case. Inthe example of a square case (i.e., a case with a square footprint), themajor and minor panels would be same size. The case 10 may be made orcardboard, chipboard, or other material, depending on job requirements.

In the example, the major panel 12 is connected to the minor panel 14along a score line 16. A score line or channel line, such as score line16, is a recess or indentation that promotes a leaner, more even fold.The fold at the score line 16 will be made when the knocked-down case 10is erected.

The major panel 12 is attached to an upper major flap 18 at score line20 and is attached to a lower major flap 22 at score line 24. The minorpanel 14 is attached to an upper minor flap 26 at score line 28 and alower minor flap 30 at score line 32.

The knocked-down case 10 has a fold 34 between the major panel 12 and aminor panel (not seen in this view). The knocked-down case 10 also has afold 36 between a major panel (not seen in this view) and a minor panel14.

The upper major flap 18 is bounded by a longer or major edge 40 andshorter minor edges 42, 44. The upper minor flap 26 is bounded by alonger or major edge 46 and shorter minor edges 48, 50.

The lower major flap 22 is bounded by a longer or major edge 52 andshorter minor edges 54, 56. The lower minor flap 30 is bounded by alonger or major edge 58 and shorter minor edges 60, 50.

At gap is defined between edge 44 of the upper major flap 18 and theedge 48 of the upper minor flap 26. The gap reduces contention andbinding between the flaps 18, 26 as one is closed. A gap that is toowide may result in a sealed case that does not fully enclose itscontents. A gap that is too narrow may result in binding, flap-conflictand failure as the flaps of the case to close during the erecting and/orsealing processes. Gaps are defined between both upper major flaps andadjacent upper minor flaps. Gaps are also defined between both lowermajor flaps and adjacent lower minor flaps. Such gap widths and/or arange of widths may be indicated by a case specification.

During manufacture of the knocked-down case 10, the tab 38 may be glued,taped or otherwise fastened, typically to an inside surface of the minorpanel 14. While the tab 38 is shown attached at a score line 16 of theminor panel 14, the score line could alternatively be folded.Alternatively, the score line could be part of the major panel 12, andthe tab could be glued to the minor panel 14. As shown, the knocked-downcase 10 may be considered a “left hand case,” because the major panel isto the left of the “seam” (the glued flap 38). The seam where the majorflap 12 and minor flap 14 are connected by the glued tab 38 may also becalled a “manufacturer's joint,” since it is a connection made by themanufacturer of the knocked-down case. This is in contrast to the tapedor glued flaps that are sealed in the course of case-erection, and(after the erected case is filled with product) case-sealing.

FIG. 1B shows the reverse side of the knocked-down case 10. Accordingly,the glued tab or flap 38 is on the opposite side. A second major panel64 (the first major panel 12 is seen in FIG. 1A) has height 66 and width68. A second minor panel 70 has height 72 and width 74. A second uppermajor flap 76 has height 78 and width 80. A second lower major flap 82has height 84 and width 86. A second upper minor flap 88 has height 90and width 92. A second lower minor flap 94 has height 96 and width 98.

FIG. 1B also shows that the distance between two features of aknocked-down case may be measured twice. Comparison of the twomeasurements can provide information on the “squareness” of aknocked-down case (or a case in the process of manufacture). In theexample shown, the width 68 of the major panel 64 is measured at 68 and99. If the measurements are the same, the panel is “square,” andadjustment may not be required (such as by a flap-closing orscore-folding tool). However, if the measurements 68 and 99 are not thesame, adjustment to the actions of one or more case-handling tools maybe indicated.

FIG. 1C shows an example data acquisition system 100. The dataacquisition system 100 may be controlled at least in part by theprocessor 102, programming and data in memory 104, and/or a database106, which may be defined in the memory 104 or an alternative location.The memory icon 104 is representative of RAM, ROM, processor memory,disks, etc.

In example operation, a sensor apparatus scans a knocked-down case 10 todetermine one or more dimensions of the case. In the example shown, thedata acquisition system 100 may include a camera 108. The camera 108 maybe supplemented by laser(s), which may simplify the scanning process.

The camera 108 is representative of any data acquisition system,including systems based on optical sensors, mechanical tools (e.g.,calipers), electro-magnetic devices, sonar, radar, infrared, and othertechnologies. Mechanical sensors may include calipers, probes, plates,or other tools that press against and/or otherwise determine a size of acase or part of a case. Hybrid systems may be used, such as a partlyoptical and partly mechanical system. One or more sensor apparatus 108may be configured to accurately measure distances between edges, scores,folds, taped or glued seems, etc. of the knocked-down case 10. In someexamples, one side of the knocked-down case 10 is measured, while inother examples both sides are measured. In an example, a camera 108 maybe supplemented by lasers, which “paint” a grid on the knocked-down casethat assists in the

In the example, the knocked-down case 10 is shown in within a magazineor cassette 110, which may contain a plurality of knocked-down cases.The magazine 110 is representative of any of: a cassette; a stagingarea; and/or any other location suitable for viewing, scanning and/ormeasuring the knocked-down case 10. The knocked-down case 10 is alsoshown separated within a cassette or magazine, to show to dimensions 68,74 that are representative of the areas of measurement (e.g.,measurements shown in FIG. 1B) that may be measured by the dataacquisition system 100.

In an example, indicia 112 may be associated with the case 10. Theindicia may include any type of printed, scannable, or other type ofinformation-conveying technology. In examples, the indicia comprise a QRcode 112, bar code, text, etc. In one example implementation, theindicia (e.g., a barcode or QR code) may be a link to a website, whichallows the system 100 to download information over the internet or othernetwork 114 from a remote server 116.

The indicia 112 may include data related to: the type or name of thetype of the case; the dimensions of that type of case; and/or thedimensions of the specific case (i.e., the case on which the indicia areprinted); or other data.

In examples identifying the type of case, the type be identified byindustry terms, a name or model number of the case, or other identifyinginformation.

In some examples, the standardized or specification-dimensions or rangesof dimensions of the case-type may be included. Such data may includespecified dimensions for a knocked-down case and/or for an erected case.The data may indicate a material of the case, a weight of the case, etc.The dimensions may include little detail (e.g., Width=10″, Length=18″,Height=8″). The dimensions may include much greater detail, such as thedimensions described by FIG. 1B and/or additional dimensionalinformation. Any desired information may be included, as need for aparticular implementation.

The indicia (e.g., QR code) may also include the actual measureddimensions of the specific case having the indicia. Accordingly, thecase type, case specifications, and actual case measurements may all beavailable. The actual measurements may include some or all of themeasurements discussed with respect to FIG. 1B and/or othermeasurements.

The data acquisition system 100 may be controlled by a processor 102 andcomputer instructions defined in a memory device 104 (shown by genericgraphic that represents any type of random-access memory (RAM) device,read-only memory (ROM) device, internally-defined or stored processorinstructions, etc.).

In operation, the data acquisition system 100 may use scanner(s) toobtain a plurality of measurements of the knocked-down case 10.Measurements may be made between any two case aspects (e.g., mix ormatch), such as edges, scores, folds, taped or glued seems, etc. Inseveral examples (meant to be only a representative list and not anexhaustive list), a length 68 of the knocked-down case 10 may bemeasured between a folded edge 34 and a score 16. In another example, awidth 74 of the knocked-down case 10 may be measured between a foldededge 36 and the score 16. A height of the knocked-down case may bemeasured between an upper edge 40 of an upper flap 18 and a lower edge52 of a lower flap 22. Other measurements may be made to determine thedimensions of upper minor flaps, upper major flaps, minor panels, majorpanels, lower minor flaps, lower major flaps, spacing between adjacentupper flaps, spacing between adjacent lower flaps, etc.

A specification or specification database 106 for knocked-down case(s)may include preferred or target measurements for a plurality of aspectsof the knocked-down case. Additionally, or alternatively, ranges ofpreferred or target measurements for a case may be included in thespecification database 106. The system 100 may be controlled at least inpart by the processor 102, memory 104 and/or database 106.

Control signals 118 may be generated by the processor 102 and sent toany case-handling tool (e.g., scanner 108 and/or any of the toolsassociated with FIGS. 1-15 , etc.).

FIG. 1D shows an example system 116 to inspect and assembly knocked-downcases. In an example, the system includes a processor 102, incommunication with the memory device 104. A measuring component 118 maybe configured a scanner (e.g., scanner 108 of FIG. 1C) to obtain ameasurement of an aspect of the knocked-down case. Alternatively, themeasuring component 118 may obtain measurements by means such as readinga QR code or other indicia from the case, or obtaining the measurementsfrom remote servers 116 over networks 118 (e.g., the internet).Accordingly, the measuring component 118 obtains the measurements, whichmay have been measured locally, remotely, etc.

A calculation component 120 may be used to determine a differencebetween the obtained measurement and a standard measurement. In anexample, the calculating component 120 may be programming executed bythe processing unit 102, and may be defined in memory (e.g., device104).

One or more programming components 122 may be executed by the processor102. In an example, the programming component generates control signals118 to operate one or more case-handling tools, such as the toolsdiscussed at FIGS. 1 through 23 . In an example, each of a plurality ofprogramming components is associated with, and provides control signalsto, a respective one of a plurality of case-handling tools.

Each programming component 122 may be configured based at least in parton output from at least one of the measuring component 118 and thecalculation component 120. In an example, adjustment of each programmingcomponent may be required, based on the differences in measurements fromstandard measurements and/or standard ranges of measurements. Suchadjustment or configuration may be performed by use ofvariable-settings, input- or adjustment-data, substituted programstatements, etc. Accordingly, some adjustment of the control signals 118may result based on input from the measuring component 118 and/orcalculation component 120.

FIGS. 2 through 14 show different stages in the assembly of a case.

FIG. 2 shows an example system 200 to adjust a pick-off point 202 of aknocked-down case 10, e.g., based at least in part ondimension-information obtained by a system (e.g., system 100 of FIG. 1). The system 200 may be controlled at least in part by the processor102, memory 104 and/or database 106. The system 200 may include arobotic arm 204, end-of-arm tool 206, which may receive control signalsbased at least in part on actions of the processor 102, memory 104and/or specification database 106. The pick-off point 202 is thelocation of the knocked-down case 10 at which the end-of-arm tool 206connects to the case. By adjusting the pick-off point, the location atwhich the case 10 is placed by the robotic arm 204 is also adjusted.Such adjustment may compensate for one or more parts of the case 10having sizes that are slightly out of specification or out of a range ofspecifications.

In example operation, the pick-off point 202 may be adjusted based atleast in part on dimensions and/or a difference between one or moredimensions of the knocked-down case 10 and dimensions within thespecification database 106. Thus, by grasping the case at an appropriatelocation on the case (e.g., based at least in part on one or moredimensions of the knocked-down case) a particular part of the case 10may be accurately located at a particular location by the end-of-armtool 206.

In the example, the major panel 12 of the case 10 may have a height 66and a width 68. By adjusting the location of the pick-off point 202, aparticular part of the case (e.g., the leading or trailing panel) may becontrolled. Without the adjustment, if one or both of these dimensionsis out-of-specification, then the robotic arm may deliver a part of thecase (e.g., the leading minor panel) to the wrong location (e.g., basedon an erroneous assumption of the case-length). However, a compensationfor a difference in case length (e.g., one-eighth of an inch) could bemade by adjusting the pick-off point (e.g., by one-eighth of an inch).

In an alternative, the pickoff-point of the case that is grasped by theend-of-arm tool could be consistent, and the location of the particularpart of the case could be controlled by adjustment to movements of therobotic arm 204 and/or end-of-arm tool 206. Both techniques providemeans to locate a particular edge, panel or other portion of the case ata particular location and/or orientation, while taking into accountslight variations in the size of one or more aspects of the case, in aknocked-down and/or a partially or fully erected configuration.

FIG. 3 shows an example system 300 to adjust a location within aconveyor system at which a knocked-down case or partially erected case10 is placed, e.g., based at least in part on dimension-informationobtained by a system (e.g., system 100 of FIG. 1 ). Accordingly, thecase is correctly located (e.g., on the conveyor or other location),based at least in part on dimensions of the case and/or variations ofthe dimensions of the case from a specification. The system 300 may becontrolled at least in part by the processor 102, memory 104 and/ordatabase 106. The system 300 may include a robotic arm 204, end-of-armtool 206, processor 102, memory 104 and specification database 106. Inan example, the system 300 may utilize dimensions 66, 68 from the casein its knocked-down configuration to determine the location for therobotic arm 204 to move the end-of-arm tool 206 so that the case isproperly located. While the example system 300 locates a part of thecase with respect to a location on a conveyor, similar systems couldlocate any portion of the case in any location with respect to any itemof machinery, product or other object.

By adjusting the location at which the robotic arm places the partiallyerected case 302, the case may interact with various tools, such as aleading-edge plow, a conveyor assembly, side-belts of a conveyorassembly, or others. Such adjustment may compensate for one or moreparts of the case having sizes that are slightly out of specification orout of a range of specifications. In an example, if measurement of aknocked-down case is slightly out-of-specification in the verticaldirection, the elevation of that case in a partially erected form mayresult in more accurate use of a leading-edge minor flap plow. That is,the plow may more accurately contact the leading minor (smaller) flap,thereby folding the flap in preparation for folding the trailing minorflap, the major flaps, and for taping the bottom of the case into aclosed configuration.

FIG. 4 shows an example system 400 to adjust a location at which aknocked-down case or partially erected case 10 is placed, e.g., based atleast in part on dimension-information obtained by a system (e.g.,system 100 of FIG. 1 ). The system 400 may be controlled at least inpart by operation of the processor 102, memory 104 and/or database 106.The example system 400 including a conveyor system having a sidebelt-drives to advance the case. A distance between the left belt-drive402 and the right belt-drive 404 may be adjusted to compensate forand/or accommodate a case having a width 74 of minor panel 14 that isslightly wider or narrower than a specification and/or expectation.Thus, the side belt-drives 402, 404 are separated by a width that istailored for the width of the case 10. The distance between theside-belt drives 402, 404 may be based at least in part on differencesbetween dimensions of the knocked-down case (e.g., the width 74 of theminor panel 70) and specifications for the case. In an example, if themeasured difference is outside of the specification, and/or differentfrom a previously handled case, then the distance between the sidebelt-drives is adjusted.

FIG. 5 shows a system 500 to adjust the position of knocked-down casesin a magazine or cassette, e.g., based at least in part ondimension-information obtained by a system (e.g., system 100 of FIG. 1). The system 500 may be controlled at least in part by the processor102, memory 104 and/or database 106. The system 500 may adjust theposition of one or more knocked-down cases 10 in a magazine, cassette,stack, etc. The adjustment may advantageously position a topknocked-down case (on the stack) for pickup by a robotic arm andend-of-arm tool. In an example, the height 66 and width 68 major panel12 and/or the height 72 and width 74 of the minor panel 14 may be usedin the adjustment process. In the example, if one of these dimensions isoff, the system 500 may adjust the location of the case 10, so that therobotic arm attaches to the correct spot (the pick-off point) of thecase. The adjustment in location may alternatively be performed for anyother reason, depending on system design. The adjusted position of theknocked-down case may be based at least in part on differences betweendimensions of the knocked-down case and specifications for the case. Inthe example shown, Y-axis movement along rail 502 and X-axis movementalong rail 504 allow the position of the uppermost case to be adjusted,so that a preferred pickoff-point on the case is positioned in alocation at which the robotic arm and end-of-arm tool expect and grasp.

In an example, an entire cassette (or stack or bundle) of cases may havebeen pre-measured, and the dimensions and/or differences between one ormore dimensions of each knocked-down case may be copied into memory 106and read by processor 102. Accordingly, the data-gathering phase of FIG.1C may be unnecessary.

In an alternative example, the robotic arm and end-of-arm tool mayadjust the location to which the tool is moved, based at least in parton the dimensions of a particular case.

The knocked-down case 10 is seen within the cassette and system 500. Thecase 10 is also shown separately to show detail.

FIG. 6 shows a system 600 adapted to make changes to movement of tool(s)based at least in part on dimension-information obtained by a system(e.g., system 100 of FIG. 1 ). In an example, a robotic arm 204 andend-of-arm tool 206 may move through a different path 602, 604 based inpart on a size of a case 10 being processed and/or how the size differsfrom a specification for the case. The case 10 may be a knocked-downcase, a partially erected case, or a fully erected case. The case may ormay not be packed with product. In the example shown, the system 600includes a robotic arm 204 and end-of-arm tool 206. The movement 602,604 of the robotic arm 204 and end-of-arm tool 206 is based at least inpart on obtained dimensions (measured dimensions or dimensionalinformation read from a source) of the knocked-down case, and/orspecifications for the case, and/or differences between the obtaineddimensions and specified dimensions. The data including actual casedimensions and specified case dimensions may be included in the memory104 and/or specification database 106. The system 600 may be controlledat least in part by the processor 102, memory 104 and/or database 106.

FIG. 7 shows a system 700 adapted to make changes to movement of aleading flap 58 closing tool based at least in part ondimension-information obtained by a system (e.g., system 100 of FIG. 1). The system 700 may include a leading minor flap plow 702 operated toadjust an elevation of the plow based at least in part on differencesbetween dimensions of a partially erected case and specifications forthe case. In an example, an elevation of a leading minor flap plow 702is based in part on a size of a case being processed.

FIG. 7 also shows a knocked-down case 10, which is shown separately fromthe plow 702 to avoid obscuring the plow. A measurement 96 of a minorpanel 58 may be used to determine, at least in part, an elevation of theleading minor flap plow 702. FIG. 7 also shows left and rightdrive-belts 402, 404 of a conveyor system, and a tape head. The system700 may be controlled at least in part by the processor 102, memory 104and/or database 106.

The case may be a partially erected case, and the leading flap plow 702may be configured to contact and to close a leading minor flap bybending it along a score line 32. In the example shown, the system 700adjusts the elevation of the plow 702. The adjustment may be based atleast in part by a height 72 of the leading minor panel 14. In theexample, if the leading minor panel 14 is slightly larger/smaller than aspecification for the case, then the plow 702 may be lowered/raisedslightly, to more correctly position the plow for contact with theleading minor flap 14. Alternatively or additionally, the height 96 ofthe minor flap 58 may be utilized. Alternatively or additionally, theheight of leading minor flap plow 702 based on a previous case that wasplowed may be considered. Data including actual case dimensions andspecified case dimensions may be included in the memory 104 and/orspecification database 106. The system 700 may be controlled at least inpart by the processor 102, memory 104 and/or database 104.

FIG. 8 shows a system 800 adapted to make changes to operation of amajor-flap closing tool, e.g., based at least in part ondimension-information obtained by a system (e.g., system 100 of FIG. 1). The system 800 may include a major flap plow (e.g., with two “jaws”802, 804 or “side-kickers”) and example operation wherein operatingparameters of the plow are adjusted based at least in part on dimensionsof a case and/or differences between actual dimensions of a case to beclosed and intended dimensions in a specification for the case and/or alocation of the side-kickers after operations on a previous case.

FIG. 8 also shows a knocked-down case 10, which is shown separately fromthe major flap kickers 802, 804 to avoid obscuring the plow. FIG. 8 alsoshows left and right drive-belts 402, 404 of a conveyor system, and atape head. The system 800 may be controlled at least in part by theprocessor 102, memory 104 and/or database 106.

The case may be a partially erected case, and the major flap kickers802, 804 may be configured to contact and to close the pair of lowermajor flaps by bending each along its respective score line. In theexample shown, the system 800 may make one or more adjustments to theoperation of the major flap plow. The adjustments may be based theheight 66 and/or width 68 of one or both of the major panels 12, 64, andbased on the height 84 and/or width 86 of one or both major flaps 22,82. The adjustments may be based at least in part on differences betweenthese measurements and specified measurements and/or ranges ofmeasurements. The adjustments may be based at least in part on alocation of the major flap kickers resulting from prior use.

In a first example, the system 800 may adjust the elevation of the plow802, 804. In a second example, the system 800 may adjust a degree towhich jaws 802, 804 of the plow are opened. In a third example, thesystem 800 may adjust timing of when the jaws are closed. In a fourthexample, the system 800 may adjust a degree to which the plow ispositioned upstream or downstream within the conveyor flow. One or moreof the adjustments may be performed, based on design parameters and theability and/or need to make such adjustments. Data including actual casedimensions and specified case dimensions may be included in the memory104 and/or specification database 106.

FIG. 9 shows a system 900 adapted to make changes to operation of a tapehead (tape application tool) based at least in part on informationobtained by a system (e.g., system 100 of FIG. 1 ) that obtainsdimensional information. The system 900 may include a tape head 902 andtape roll 904. In example operation, operating parameters of the tapehead are adjusted based at least in part on dimensions of a case and/ordifferences between actual dimensions of a case to be closed andintended dimensions in a specification for the case and/or a previouslocation of the tape head due to operations on a previous case.

FIG. 9 also shows a knocked-down case 10, which is shown separately fromthe tape head 902, 904 to avoid obscuring the tape head. FIG. 9 alsoshows left drive-belt 402 of a conveyor system. The system 900 may becontrolled at least in part by the processor 102, memory 104 and/ordatabase 106.

The case may be a partially erected case, and the tape head 902 may beconfigured to contact and to seal the pair of lower major flaps byapplying tape to both major flaps. In the example shown, the system 900may adjustments to the operation of the tape head. The adjustments maybe based the height 66 and/or width 68 of one or both of the majorpanels 12, 64, and based on the height 84 and/or width 86 of one or bothmajor flaps 22, 82. The adjustments may be based at least in part ondifferences between these measurements and specified measurements and/orranges of measurements. The adjustments may be based at least in part ona location of the tape head resulting from prior use.

In a first example, the system 900 may adjust the elevation of the tapehead 902, and optionally the tape spool 904. In a second example, thesystem 900 may adjust a timing of tape application. In a third example,the system 900 may adjust timing of tape cutting. In a fourth example,the system 900 may adjust a timing of contact with a leading minor paneland timing of kicking tape onto a trailing minor panel. One or more ofthe adjustments may be performed, based on design parameters and theability and/or need to make such adjustments. Data including actual casedimensions and specified case dimensions may be included in the memory104 and/or specification database 106.

FIG. 10 shows a system 1000 adapted to make changes to operation of aglue head (glue application tool) based at least in part on informationobtained by a system (e.g., system 100 of FIG. 1 ) that obtainsdimensional information. The system 1000 may include a glue head 1002.In example operation, operating parameters of the glue head are adjustedbased at least in part on dimensions of a case and/or differencesbetween actual dimensions of a case to be closed and intended dimensionsin a specification for the case and/or a previous location of the gluehead due to operations on a previous case.

FIG. 10 also shows a knocked-down case 10, which is shown separatelyfrom the tape head 1002 to avoid obscuring the glue head. FIG. 10 alsoshows left and right drive-belt 402, 404 of a conveyor system. Thesystem 1000 may be controlled at least in part by the processor 102,memory 104 and/or database 106.

The case may be a partially erected case, and the glue head 1002 may beconfigured to contact and to seal the pair of lower major flaps byapplying glue to at least one major flap. In the example shown, thesystem 1000 may adjustments to the operation of the glue head. Theadjustments may be based the height 66 and/or width 68 of one or both ofthe major panels 12, 64, and based on the height 84 and/or width 86 ofone or both major flaps 22, 82. The adjustments may be based at least inpart on differences between these measurements and specifiedmeasurements and/or ranges of measurements. The adjustments may be basedat least in part on a location of the glue head resulting from prioruse.

In a first example, the system 1000 may adjust the elevation of the gluehead 902. In a second example, the system 1000 may adjust a timing ofglue application. In a third example, the system 1000 may adjust timingof pressure applied to areas of glue application. One or more of theadjustments may be performed, based on design parameters and the abilityand/or need to make such adjustments. Data including actual casedimensions and specified case dimensions may be included in the memory104 and/or specification database 106.

FIG. 11 shows a system 1100 adapted to make changes to operation of aconveyor assembly, e.g., based at least in part on information obtainedby a system (e.g., system 100 of FIG. 1 ) that obtains dimensionalinformation. The system 1100 may include a conveyor 1102 and controlsystem(s) to adjust conveyor operation and flight lug location based atleast in part on: dimensions of a case to be handled; differencesbetween actual dimensions of a case to be handled and intendeddimensions (e.g., in a specification for the case); and/or locations ofthe flight lug(s) after handling a previous case. Based on such data,the system 1100 may control conveyor start times, stop times, speed, andlocations of flight lugs 1104, 1106 of the conveyor assembly (e.g.,flight lugs designed to push cases along the conveyor assembly). In anexample, a slight difference in case length (e.g., major panel length68) may indicate a slight difference in the timing, speed and/orlocation at a given time of the flight lugs 1104, 1106, which contactand push the trailing minor panel 14 of the case.

FIG. 11 also shows a knocked-down case 10, which is shown separatelyfrom the conveyor assembly 1102 to indicate possible measurements inputto the system 1100. In an example, a measurement of a length 68 of amajor panel of a case may be used to determine, at least in part,locations and movement of flight lugs on a conveyor assembly. In anexample, the system 1100 may be controlled at least in part by theprocessor 102, memory 104 and/or database 106.

FIG. 12 shows a system 1200 including a trailing minor flap kicker(s)and example operation wherein operating parameters of the kicker(s) areadjusted, based at least in part on dimension-information obtained by asystem (e.g., system 100 of FIG. 1 ). After the leading minor flap isfolded, the two major flaps are folded, and then the trailing minor flapis folded, typically by one or more “flap kickers” 1202, 1204. Inexamples, the location of the kicker(s), timing of the “kick” of theminor flap that folds that flap along its score line 32 adjacent thetrailing minor panel 30, and/or separation of two or more kickers 1202,1204 is controlled by programming and/or control systems based at leastin part on dimensions and/or difference(s) of dimension(s) frompreferred dimension(s) and/or ranges of dimension(s). In an example, adistance between two kickers 1202, 1204, and a distance between eachkicker and an adjacent edge of the trailing minor flap 30, may beadjusted based at least in part on a width 98 of the trailing minor flap30. In a further example, timing of the kick may be based at least inpart on the height 96 of the trailing minor flap 30 and/or the length 68of a major panel 30. The longer these dimensions are, the more the timeof the kick can be delayed, so that the kick strikes the trailing minorflap at a location that results in a better fold at the score/fold line32. Data including actual case dimensions and specified case dimensionsmay be included in the memory 104 and/or specification database 106. Inan example, the kickers 1202, 1204 may be rotated on an axle. As thecase 10 moves over the kickers, the kickers may be rotated to a locationbelow a level of the case. However, as the case begins to pass thekickers, the kickers may be rotated to “kick” the trailing minor flap30, and to thereby bend the trialing minor flap along the score 32.

FIG. 13 shows a system 1300 including glue mandrel (e.g., to glue lowerflaps of a case. In example operation, the system 1300 may adjustoperating programming, data and/or variables used to control themandrel, based at least in part on dimension-information obtained by asystem (e.g., system 100 of FIG. 1 ).

FIG. 13 shows structure and operation of a mandrel, which can beadjusted to fit a size of the bottom of a partially erected case, tohold major and minor lower flaps in position, and to glue the flapsclosed. The operation of the mandrel may be controlled by programmingand/or control systems based at least in part on: dimensions of thecase; and/or difference(s) of dimension(s) from preferred dimension(s)and/or ranges of dimension(s); and/or a previous configuration of themandrel. Data including actual case dimensions, specified casedimensions/ranges, and/or differences between such dimensions may beincluded in the memory 104 and/or specification database 106.

The system 1300 may include a glue mandrel 1302 having a base 1304 thatis adjustable in size (e.g., having an adjustable footprint). Theadjustability allows for correction of slight differences in thedimensions of the case, caused by slight imperfections in the size ofthe major panels and/or minor panels of the case.

In example operation, the glue mandrel 1302 is lowered into a partiallyerected case. The base 1304 of the glue mandrel is adjusted in size notto the specified size of the case, but to the actual measured size ofthe case. In the example shown, the measured length 74 of the minorpanel 14 (i.e., the width of the case 10 and the measured length 68 ofthe major panel 12, can be used to determine a size to which to adjustthe base 1304 of the mandrel 1302. Accordingly, the measurements 68and/or 74 allow adjustment of the base 1304 to better fit the actualcase, and not a case specification. In an example, the system 1300 maybe controlled at least in part by the processor 102, memory 104 and/ordatabase 106, which may include at least the measurements 68 and 74.

FIG. 14 shows structure and operation of a flap spreader assembly 1400,which can be operated to hold the major flaps of a case so that one ormore of the leading minor flap and the trailing minor flap may be foldedinto a closed position or orientation. Accordingly, the flap spreaderassembly prevents unwanted contact between flaps, particularly byholding the major (larger) flaps while one or more minor flaps isclosed. The operation of the flap spreader assembly 1400 may becontrolled by a processor 102, programming, and/or control systems basedat least in part on dimensions and/or difference(s) of dimension(s) frompreferred dimension(s) and/or ranges of dimension(s). Programming anddata including actual case dimensions, specified case dimensions/ranges,and/or differences between such dimensions may be included in the memory104 and/or specification database 106.

The flap spreader assembly or system 1400 may operate in a manner basedat least in part on dimension-information obtained by a system (e.g.,system 100 of FIG. 1 ). In the example shown, flap spreaders 1402 and1404 hold the major flaps open so that the minor flaps can be closed. Inan example, if a notch 1406 between a minor flap 26 and a major flap 18is too small, there may be contention, rubbing and/or binding betweenthe minor flap(s) and the adjacent major flap(s) when the minor flapsare folded along their score lines in a flap-closing process. Becausethe flap spreading assembly 1400 is able to hold the major flaps open,other assemblies are able to close the minor flaps. In exampleoperation, the system 1400 may be controlled at least in part by theprocessor 102, memory 104 and/or database 106, which may includemeasurements 1406, 80, 92 and/or other measurements.

One or more operating parameters of the assembly 1400 may be adjustedbased at least in part on differences between dimensions of a partiallyerected case and specifications for the case. In an example, if the gap1406 between adjacent flaps is too small, the flap spreader assembly1400 may be utilized. If the gap is appropriately sized or within arange, the flap spreader assembly 1400 may not be used. Thus, the system1400 may utilize programming, data and/or variables to control the flapspreader(s) 1402, 1404 based at least in part on obtained dimensionalinformation.

FIG. 15 shows a system 1500 including a decision process and associatedmechanical apparatus for distinguishing and separating knocked-downcases that can, and cannot, be assembled into erected cases within aspecification. The system 1500 may operate based at least in part ondimension-information obtained by a system (e.g., system 100 of FIG. 1). In the example shown, the processor 102, software defined in a memoryunit (represented by generic memory icon 104) and a specificationdatabase 106 execute an algorithm that distinguishes knocked-down casesthat can or cannot be assembled to within the specification. In theexample shown, a robotic arm 204 and end-of-arm tool 206 are shownrejecting a case 10 based on out-of-specification characteristics thatcannot be resolved by application of one or more of the techniquesdescribed in association with FIGS. 1-14 .

Example Methods

FIG. 16 shows a method 1600 and example operation of a system configuredto measure a case while in a folded-flat configuration and erect thecase based in part on the measurements.

At block 1602, a folded-flat case is measured.

At block 1604, determining if the measurements indicate erecting thecase, or discarding the folded-flat case.

At block 1606, if erecting is indicated, then using the measurements atleast in part to adjust a machine to successfully erect the case.

At block 1608, measuring the erected case.

At block 1610, determining if the measurements indicate filing/loadingthe case with product, or discarding the erected case.

FIG. 17 shows a method 1700 and example operation of a system configuredto measure a case or carton while in a folded-flat configuration.

At block 1702, a folded-flat case is separated from other folded-flatcases in a cassette, in a process called singulation. Either before orafter singulation, dimensions of the folded-flat case are measured.Accordingly, block 1702 may be performed before or after any of theblocks 1704 through 1716. Accordingly, the separation is also shown atblock 1718. In an example, if the measuring processes are performed by acassette or other knocked-down case containing or managing system, thenthe separation may happen at block 1718. The dimensions may be measuredby operation of one or more sensors, cameras, lasers, mechanicaldetectors, and/or other tools. Such tools may be part of a cassette ormagazine (e.g., 110 of FIG. 1C). The dimensions that may be measured mayinclude (but are not limited to) distances between one or more of: edgesof the cardboard, scores in the cardboard, and/or a manufacturer's seamalong which the cardboard has been glued. The manufacturer's seam mayinclude an outside manufacturer's seam where the cardboard edge is ontop of the cardboard to which it is glued.

At block 1704, a width of the folded-flat case is measured. In anexample, a distance between opposed folded corners (i.e., the paralleledges of folded-flat case) may be measured.

At block 1706, a height of the folded-flat case is measured. In anexample, a distance between an edge of an upper flap to an edge of alower flap may be measured.

At block 1708, a distance between a manufacturer's seam in thefolded-flat case and at least one other feature of the folded-flat case,such as the edge of the case, may be measured.

At block 1710, a distance between opposed scores, which upon erection ofthe case form the corners of the case (i.e., the scored parallel edgesof folded-flat case) may be measured.

At block 1712, a distance between a score associated with an upper flapand an edge of the upper flap may be measured.

At block 1714, a distance between a score associated with a lower flapand an edge of the lower flap may be measured.

At block 1716, a width and location of one or more flaps may be comparedto scores defining the face of the case upon which the flap is hinged.The flaps may be a prescribed width that is narrower than the distancebetween scores (to allow the flaps to be folded). An edge of each flapmust be inset from each score by a distance that allows the flap to befolded. The flaps include four upper flaps (two major flaps and twominor flaps) and four lower flaps (two major flaps and two minor flaps).In the circumstance of a case having a square footprint, the distinctionbetween upper and lower flaps may be based on orientation of the case,with the first-closed flaps being the “minor flaps.”

In some examples, the following measurements are used:

Manufacturer's seam location. The seam, which may be include two edgesof cardboard that are glued together, may have been fastened in a mannerthat differs from specifications.

Manufacturer's seam straightness may require measurement and may beoutside of tolerances.

The manufacture's seam should ensure that the top and bottom areparallel (at least within tolerances) where they meet.

FIG. 18 shows a method 1800 and example operation of a system configuredto determine if measurements of a folded-flat case are sufficientlywithin tolerances, or if the case must be discarded. Individualmeasurements may be considered, as well as combinations of measurements,which may cause problems collectively.

At block 1802, one or more measurements of a folded-flat case areobtained.

At block 1804, a predication is made about whether availablecase-erecting machinery would (1) be able to erect the case, and/or (2)if the quality or exactness of the resulting case is within tolerances.The predication(s) may be based on one or more of the measurements made,as well as any other information, such as a range of acceptable finalassembled case dimensions. The prediction(s) may be somewhat simple,such as if one measurement is out of tolerances, the prediction is forfailure. The prediction may be somewhat more complex, in that severalmeasurements, none of which alone is enough to predict failure for thecase, may collectively be enough to predict failure for the case.

In an example, one or more of the following measurements may be made.The measurements may be used individually and/or collectively todetermine if a knockdown case dimensions were within a thresholddifference-value (positive or negative) of established and/or specifiedvalues.

-   -   Height    -   Width    -   Lower score line distance from upper edge    -   Upper score line distance from upper edge    -   Distance between score line    -   Manufacturer's seam straightness    -   Manufacturer's seam distance from each edge    -   Manufacturer's seam alignment    -   Width of each flap    -   Height of each flap

If any of the following conditions are met, the knockdown case would berejected.

-   -   Manufacturer's seam is more than a pre-set amount out of        straightness tolerance.    -   Manufacturer's seam location is more than a pre-set amount out        of tolerance.    -   Manufacturer's seam miss-aligns the top and bottom of the case.    -   Score line is not parallel with the edges by more than a pre-set        percent.    -   Flap width equals or exceeds side of case dimension    -   Flap height is more than half height of side

At block 1806, a determination is made to use the case or to reject thecase. The determination may be based on a predicted outcome of thenature and precision of the erected case, which was made at block 204.The determination may also be based on a degree to which compensationfor unfavorable measurements is expected to succeed. In some situations,a sloppy case may be more accepted than other situations. For example,if bagged food is to be loaded into the case, the bags may push on thesides and make the case look uneven even if it was erected withprecision. In such circumstances, it may be a low-quality case may beacceptable. However, if jars of food are to be loaded into the case, ahigher precision may be required. We can set the decision to use/not-useat block 206.

FIG. 19 shows a method and example operation 1900 of a system configuredto assemble the case based in part on information obtained frommeasuring the case while in a folded-flat configuration.

At block 1902, adjustments may be made to the operation of a machineassembling and/or erecting the case to compensate for irregularitiesand/or characteristics of the folded-flat case. The adjustments mayanticipate problems with the case-erection process and overcome thoseproblems. The adjustments may be made in anticipation problems thatwould otherwise plague the case-erection outcome, and thereby result ina better outcome.

In an example, cases may vary from preferred and/or expected dimensionsand/or conditions. Example adjustments that may be made to the machineto accommodate example variances in case dimension are discussed below.

At block 1904, compensations may be made, based at least in part on alocation of a seem (e.g., glued connection) in knocked-down caseobtained from a manufacturer. Should the seam location vary from apreferred location, either to the left or to the right, the machine mayautomatically adjust a location of a pivot point of a vacuum cupmechanism having opposed vacuum cups, to thereby align with the scoreline.

At block 1906, adjustment may be made for case height and/or distancefrom bottom score line to top of case. Should the case height or bottomscore line be different from the previous case, the machine mayautomatically adjust the top guard that provides pressure on the casewhile it transfers through the closing mechanism to align with theheight of the case when the bottom flaps are closing/closed.

At block 1908, adjustment may be made for a major side width. Should themajor side width be different than the previous case, timing of the flapfolding, glue placement or tape placement may be adjusted to align tothe new case length.

At block 1910, adjustment may be made for a minor side width. Should theminor side width differ from the previous case, the machine may adjustthe mechanism that controls the side of the case through the machine toalign with the new dimension.

At block 1912, adjustment may be made for a straightness of a seam(e.g., a glued tab) of a knocked-down case. If the seam is not straightthe machine may automatically adjust the location of the pivot point ofthe opposing vacuum cup mechanism to align with the center point of themiss aligned seam line.

At block 1914, adjustment may be made for a score line location of aknocked-down case. If the score line location is different than theprevious case, the machine may automatically adjust the position of thepick off mechanism and align the case score line with the position ofthe flap folding and sealing mechanism.

FIG. 20 shows a method 2000 and example operation of a system configuredto measure a case while in an erected configuration.

At block 2002, a case is opened, from a two-dimensional flat form to athree-dimensional opened form, in a process called case-erection.Case-erection may include a sealing step, wherein the lower flaps aretaped, glued and/or otherwise sealed. This gives the case athree-dimensional shape, and readies the case to be loaded with product.After the case is erected, dimensions of the case are measured. Thedimensions may be measured by operation of one or more sensors, cameras,lasers, mechanical detectors, and/or other tools. The dimensions thatmay be measured may include (but are not limited to) distances betweenone or more of: edges of the cardboard, scores in the cardboard, and/ora manufacturer's seam along which the cardboard has been glued. Themanufacturer's seam may include an outside manufacturer's seam where thecardboard edge is on top of the cardboard to which it is glued.

At block 2004, a width of the erected case is measured. In an example, adistance between opposed corners is measured.

At block 2006, a height of the erected case is measured. In an example,a distance between an edge of an upper flap to the sealed bottom of thecase is measured.

At block 2008, a distance between opposed corners is measured.

At block 2010, a distance between a score associated with an upper flapand an edge of the upper flap is measured.

At block 2012, a distance between a score associated with a lower flapand an edge of the lower flap is measured.

At block 2014, a measurement of the overall squareness of the case atthe bottom and top score line is measured.

FIG. 21 shows a method 2100 and example operation of a system configuredto determine if measurements of an erected (i.e., opened) case aresufficiently within tolerances, or if the case must be discarded.Individual measurements may be considered, as well as combinations ofmeasurements, which may cause problems collectively.

At block 2102, one or more measurements of an erected case are obtained.

At block 2104, a predication is made about whether availablecase-loading machinery would (1) be able to load the erect case, and/or(2) if the quality or exactness of the resulting loaded case is withintolerances. The predication(s) may be based on one or more of themeasurements made, as well as any other information, such as a range ofacceptable final assembled case dimensions. The prediction(s) may besomewhat simple, such as if one measurement is out of tolerances, theprediction is for failure. The prediction may be somewhat more complex,in that several measurements, none of which alone is enough to predictfailure for the case, may collectively be enough to predict failure forthe case.

In an example, the following aspects of a case may be measured. Casewidth may be measured to determine if an error (positive or negative) inthe case width is exceeds a threshold difference from an establishedspecification for the case. Case length may be measured to determine ifan error (positive or negative) in the case length is exceeds athreshold difference from an established specification for the case.Case height, i.e., a distance between inside bottom and top score line,may be measured to a determine if an error (positive or negative) in thecase height exceeds a threshold difference from an establishedspecification for the case.

At block 2106, a determination is made to use the case or to reject theerected case. The determination may be based on a predicted outcome ofthe nature and precision of the erected case. The determination may alsobe based on a degree to which compensation for unfavorable measurementsis expected to succeed. In some situations, a sloppy case may be moreaccepted than other situations.

FIG. 22 shows a method 2200 and example operation of a system configuredto measure a case while in a folded-flat configuration and erect thecase based in part on the measurements.

At block 2202, a measurement of an aspect of a case (e.g., the length ofthe major panel, or the gap between adjacent upper flaps, etc.) isobtained. The measurement may be obtained by actually measuring it(e.g., with an optical device including camera(s) and/or laser(s), amechanical scanner (e.g., calipers), combination technology scanner) orby reading the measurement from indicia printed on the side of the caseor by reading the measurement from a data file associated with the case.In an example, a reader device may read a bar code or QR code printed onthe knocked-down case. The code may include measurement data for thatcase, including aspects that were measured (including in-specificationand/or out-of-specification measurements).

At block 2204, a difference is determined between the obtainedmeasurement and a standard measurement and/or a range of acceptablemeasurements. Accordingly, if one or more aspects of the knocked-downcase is somewhat out-of-specification, the difference quantify thediscrepancy.

At block 2204, a difference between the obtained measurement and astandard measurement or a range of standard measurements is determined.The measurement may be in-specification, in which case there may be nodifference. The measurement may be out-of-specification, in which casethere may be a difference. If the difference is not too large, byadjusting programming to adjust control signals, to adjust case-handlingtool operation, the case may be properly erected, loaded, and/or sealed.If the difference is too large, the case may be rejected, returned to amanufacturer, and/or recycled.

At block 2206, programming is executed to control and/or to providecontrol signals for a case-handling tool. The programming, data used bythe programming, and/or values of variables used by the programming maybe based at least in part on the determined difference (e.g., differencefrom a standard value or range of values, as determined at block 2204).In an example, the case-handling tool may operate in a manner that isbased on the measured size of the knocked-down case and/or that resultsin control signals that adjust case-handling to compensate for themeasurements that are out-of-specification. As a result, thecase-handling tool is better able to erect and/or seal a knocked-downcase that is within-specification, even if the knocked-down case wasout-of-specification.

At block 2208, the case-handling tool is operated responsive to theexecuted programming to at least partially erect the knocked-down caseinto an erect case, to load the erected case with products, and/or toseal the loaded case.

FIG. 23 shows a method 2300 and example operation of a system configuredto measure a case while in a folded-flat configuration and erect thecase based in part on the measurements.

At block 2302, a measurement of an aspect of a case is obtained. Themeasurement may be obtained by any means, such as those mentioned atblock 2202 of FIG. 22 .

At block 2304, a type of case is determined. If a particular type ofcase is determined, the case type may be used to obtain the standardmeasurement and/or range of measurements for such a case, such as from aspecification database 106, specification website, etc. The type of casemay be obtained from data on the case size, data printed on the case,etc. Thus, the type of case can assist in finding the standardmeasurement and/or range of standard measurements.

At block 2306, a difference is determined between the obtainedmeasurement and a standard measurement and/or a range of acceptablemeasurements.

At block 2308, programming may be configured, such as by usingvariables, data and/or program statements, in a manner that is based atleast in part on the difference in measurement(s) of the case andstandard measurements and/or ranges of standard measurements. Executionof the programming generates and sends control signals to acase-handling tool. The programming and/or resulting control signals maybe based at least in part on the difference that was determined.

At block 2310, one or more case-handling tools are operated according tothe control signals. The case-handling tools may erect the case, fillthe case with product, and/or seal the case.

FIG. 24 shows a method 2400 and example operation of a system configuredto measure one or more aspects a case in a stage of assembly, determinedifferences between the measurements and specifications, adjustprogramming, and operate case-handling tools.

At block 2402, at least one measurement of an aspect of a case in astage of assembly is measured. The measurement may be of a knocked-downcase or raw material of a knocked-down case, such as piece of cardboard(or other material). Examples of such measurements may include (but arenot limited to) measurements of: a cut blank; a cut and scored blank; acut, scored and folded blank; or of a cut, scored, folded and gluedblank; etc. The measurement may be related to the direction (i.e.,orientation) of the corrugations in the cardboard, distances between anytwo of cut edges, scores, folds etc. One or more measurements may bemade after one or more actions, such as material rotation, one or morecuts of the material, one or more scores of the material, one or morefolds of the material, one or more glued or taped seals of portions ofthe material, etc.

At block 2404, a difference may be determined between the obtainedmeasurement and a standard measurement and/or a range of acceptablemeasurements.

At block 2406, programming may be executed to send control signals tocase-handling tool(s) and/or material handling tool(s). The programmingmay be based at least in part on the differences in measured dimensionsfrom expected dimensions. In an example, if a flap is slightly longerthan a specification, then programming may send control signals to atape head that compensate for the added length when taping the flapclosed. In examples, the programming may operate the tool(s) based onone or more factors. In the example of block 2408, control signals mayto tool(s) may be based at least in part on difference(s) betweenmeasured aspects of the knocked-down case or material. In the example ofblock 2408, the programming is based at least in part on the differencebetween obtained measurements and standard/preferred measurements and/orranges of measurements. In the example of block 2410, the stage of theassembly of the case may be considered in the programming. Differentcase-handling and/or case-manufacturing tools may be configured toperform different tasks, and differences in measurements (e.g., fromblock 2404) may be relevant only to certain tools. For example,programming for a tool configured to score cardboard may be customizedfor a particular case at a point in its construction after it has beencut, but before it has been folded (at the score).

At block 2412, the case-handling or material-handling tool(s) areoperated according to control signals that resulted as programming isexecuted. After a plurality of tools have been utilized a knocked-downcase (e.g., a case 10 of FIGS. 1A and 1B) is created.

At block 2414, indicia may be printed on the completed knocked-downcase. The indicia may include human- and/or machine-readableinformation. In an example, a QR code may be printed on the knocked-downcase. The QR code tells the user of the case the dimensions of one ormore (e.g., many) dimensions of aspects of the knocked-down case. Thisallows the scanning system 108 (e.g., in FIG. 1C) to read the QR codewithout actually measuring the case. Accordingly, the tools and actionsdescribed in FIGS. 2 through 15 may be performed based on data in the QRcode. If such a code and/or indicia is not printed on the constructedknocked-down case, the scanning system 108 may have to make the actualmeasurements used by the tools to perform the actions described in FIGS.2 through 15 .

FIG. 25 shows a method 2500 and example operation of a system configuredto measure one or more aspects of a case (or materials to make a case)in stages of manufacture, determine differences between the measurementsand specified measurements or ranges of measurements, adjustprogramming, data, variables, etc., and operate tools according to theadjusted programming, variables, parameters, etc. In an example, themethod includes some or all of: measuring an angle of the cardboardcorrugations; rotating if necessary; cutting the cardboard into a shapedneeded to make the case; measuring; scoring fold-lines; measuring;folding between a major panel and a minor pane; measuring; folding atab; measuring; gluing the tab to a major or minor panel; measuring theknocked-down case; printing indicia on the case, indicating at leastsome of the measurements. One or more of the rotating, cutting, scoring,folding of major/minor panel, folding of the tab, and/or gluing of thetab may be performed by respective tools using information derived atleast in part on the measuring steps. Accordingly, the tools operatewith more precision and effectiveness than if they made assumptionsbased on typical outcomes of previous operations. By printing indicia onthe resultant knocked-down case, machines or tools that later erect theknocked-down case will be able to operate with increased precision.

After each measuring step 2502, 2508, 2512, 2516, 2520, 2524, the datafrom the measuring may be used to adjust the operation of case-handlingtools, case-manufacturing tools, etc. Thus, the operation of each toolmay be adjusted as indicated by the measurements, such as to compensatefor any discrepancy or abnormality in the size, shape, orientation,etc., of the workpiece.

At block 2502, an angle of the orientation of corrugations of a piece ofcardboard is measured. In an example, optical techniques, in some casesinvolving back-lighting, lasers, etc., can be used to make themeasurement.

At block 2504, if indicated by the angle of orientation, the piece ofcardboard may be rotated to correct the angle. Typically, thecorrugations will be oriented “north and south” or “east and west” withrespect to machinery involved.

At block 2506, the piece of cardboard may be cut according to a shape ofa knocked-down, but not yet assembled, case (i.e., cardboard box). Thecut may be made by a tool that cuts the perimeter with a blade, or inone action in the manner of a “cookie cutter.” The cut may be madeaccording to input from the measurement made at block 2502, such as byrotating the cutter if needed, to compensate or workpiece orientation.Accordingly, a cut “blank” is formed. If the cardboard was not rotatedat block 2504, the tool may be rotated at block 2506.

At block 2508, distances between two or more edges of the cardboardblank are measured. In an example, many of the distances identified inFIG. 1B are measured. Additional and/or different distances can bemeasured depending on system design requirements. Since the blank hasnot yet been folded, measurements may be made from one side of the blankto the other side, etc.

At block 2510, the cardboard blank is scored in one or more locations,to result in creation of one or more fold-lines. Example, scoring andfold-lines are seen in FIGS. 1A, 1B, 1C. The scoring may be performedusing as input the measurements made at block 2508.

At block 2512, distances between combinations of edges and fold-linesare measured. Example measurements are seen in FIG. 1B. Since the blankhas not yet been folded, measurements may be made from one side of theblank.

At block 2514, the blank may be folded at a scored fold-line between amajor panel and a minor panel. This effectively folds the blank in half.The folding may be made using as input the measurements made at block2512.

At block 2516, distances between combinations of the fold, scoredfold-lines, and edges are measured. Example measurements are seen inFIG. 1B.

At block 2518, a tab, which is connected to either a major or minorpanel by a fold-line, is folded. Alternatively, a score between a majorand minor panel is folded. The folding may be performed according themeasurements made at block 2516.

At block 2520, distances between combinations of the folds, scoredfold-lines and edges are measured. Example measurements are seen in FIG.1B.

At block 2522, if the tab is connected to a major panel at a fold, it isglued to a minor panel. If the tab is connected to a minor panel at afold, it is glued to a major panel. The connection of the tab to a panelmay be made with glue or tape and may be made using the measurementsmade at block 2520 as input. With the tab glued, the folded blank(having been cut, scored, folded and glued) is now a knocked-down case.

At block 2524, distances between combinations of the glued seem, thefolds, scored fold-lines and edges are measured. Example measurementsare seen in FIG. 1B.

At block 2526, indicia (e.g., QR code 112 of FIG. 1C) may be printed onthe knocked-down case. The printing may be made using any of themeasurements made (e.g., measurements made at block 2524) as input tothe printing process. The indicia may be configured to transferinformation about dimensions of the case to machinery that erect, fill,and/or seal the case. Accordingly, such information may obviate the needfor such machinery to measure the knocked-down blank, while stillallowing the machinery to benefit from such information. In an example,a QR code may convey the information from the manufacturer of aknocked-down case to the buyer/user/consumer of the knocked-down case.In the example of FIG. 1C, the scanner 108 may read the QR code 112 ifavailable, or scan the dimensions (e.g., using camera(s) and laser(s))if the code is unavailable or unreadable. In a second example, a QRcode, bar code, etc., may convey a webpage address, and thedimension-information may be obtained from servers (e.g., servers 116 ofFIG. 1D) hosting the page.

In a further example of block 2526, each knocked-down case may have anID number. Additionally, each knocked-down case may publish its owndimensions, such as by QR code, website link, etc. And further,knocked-down cases may also provide ID numbers and/or dimensionalinformation about other cases, such as knocked-down cases that areadjacent to themselves in a stack or cassette of cases. Accordingly, ifcase-erecting machinery reads a QR code of a first case, it may alsoobtain the dimensional information of the next case in the cassette.This may assist the case-erecting machinery to move into a preferredposition even before the next case is scanned. In an example, theleading minor flap plow may adjust to a height of a second case afterplowing a first case, using information obtained from the first case,even before the second case is scanned or read. Similarly, a website mayknow the dimensional information for all cases in a cassette, and mayprovide that information as soon as it is useful.

In the example of block 2528, the operation of any tools (case-handling,case-manufacturing, etc.) may be performed, adjusted, etc., according todata obtained from any of the measuring steps and the sensors, cameras,lasers, etc., used in those steps. Thus, rotating, cutting, scoring,folding, gluing, taping, printing, etc., may be performed accordingprogramming, variable-settings, data, etc., that is based at least inpart on one or more of the measuring steps. While a plurality ofmeasuring steps are shown and discussed, additional, other, and/or fewermeasuring steps could be performed, as indicated by

Conclusion

While the term “cardboard” is used in the discussion as the materialused to make cases or cartons, within this document cases or cartons maybe made using any material used in commerce and such materials referredto colloquially as “cardboard.” Also, while individual measureddistances are recited, such measurements may be made in severallocations. For example, the height of a flap may be measured from thecardboard edge to the score in several locations, to confirm that thescore of the flap is parallel to the edge of the flap.

The terms knocked-down and/or folded-flat case may refer to cardboard orother boxes that have not yet been erected, and that are typicallystacked until erected, loaded, and sealed.

Although the subject matter has been described in language specific tostructural features and/or methodological acts, it is to be understoodthat the subject matter defined in the appended claims is notnecessarily limited to the specific features or acts described. Rather,the specific features and acts are disclosed as exemplary forms ofimplementing the claims.

The invention claimed is:
 1. A method to inspect and assemble aknocked-down case, comprising: obtaining a measurement of an aspect ofthe knocked-down case, wherein obtaining the measurement comprisesmeasuring distances between at least one pair of case features, whereinthe case features, comprise: an edge of the knocked-down case; a scoreof the knocked-down case; and a fold of the knocked-down case;determining a difference between the obtained measurement and a standardmeasurement; executing programming of a case-handling tool, wherein theexecuted programming is based at least in part on the determineddifference; and operating the case-handling tool responsive to theexecuted programming to at least partially erect the knocked-down caseinto an erected case.
 2. The method of claim 1, wherein: theknocked-down case comprises a corrugate, cardboard, and/or chipboardknocked-down case; and the erected case is in a condition ready forloading with product.
 3. The method of claim 1, wherein obtaining themeasurement comprises: scanning the knocked-down case to measure theaspect of the knocked-down case.
 4. The method of claim 1, whereinobtaining the measurement comprises: reading indicia defined on theknocked-down case.
 5. The method of claim 1, wherein determining thedifference between the obtained measurement and the standard measurementcomprises: determining a difference between the obtained measurement andat least one end of a range of standard measurements.
 6. The method ofclaim 1, wherein the executed programming comprises at least one of: atleast one command that is based at least in part on the determineddifference; at least one sequence of commands that is based at least inpart on the determined difference; at least one variable used by theexecuted programming that is based at least in part on the determineddifference; or at least one datum used by the executed programming thatis based at least in part on the determined difference.
 7. The method ofclaim 1, wherein: the knocked-down case has dimensions that are notwithin a specification for the knocked-down case; and the erected caseis within a specification for the erected case.
 8. The method of claim1, additionally comprising: selecting the case-handling tool from amonga plurality of case-handling tools based at least in part on whetherexecuting the programming based at least in part on the determineddifference will result in the erected case being within a specificationfor the erected case.
 9. The method of claim 1, wherein the determineddifference between the obtained measurement and a standard measurementis used to select the case-handling tool from among a plurality ofcase-handling tools and is used to determine changes to at least one ofprogramming, variables, and data used by the programming of the selectedcase-handling tool.
 10. The method of claim 1, wherein operating thecase-handling tool responsive to the executed programming comprises:operating a robotic arm and an end-of-arm tool to grasp the knocked-downcase at a pick-off location based at least in part on the differencebetween the obtained measurement and the standard measurement.
 11. Themethod of claim 1, wherein operating the case-handling tool responsiveto the executed programming comprises: operating a robotic arm andend-of-arm tool to place the erected case at a location that is based atleast in part on the difference between the obtained measurement and thestandard measurement.
 12. The method of claim 1, wherein operating thecase-handling tool responsive to the executed programming comprises:adjusting a distance between two belt drives of a side belt drive unitbased at least in part on the difference between the obtainedmeasurement and the standard measurement.
 13. The method of claim 1,wherein operating the case-handling tool responsive to the executedprogramming comprises: operating a magazine assembly to adjust alocation of the knocked-down case to be picked based at least in part onthe difference between the obtained measurement and the standardmeasurement.
 14. The method of claim 1, wherein operating thecase-handling tool responsive to the executed programming comprises:adjusting a path of travel of a robotic arm and end-of-arm tool based atleast in part on the difference between the obtained measurement and thestandard measurement.
 15. The method of claim 1, wherein operating thecase-handling tool responsive to the executed programming comprises:adjusting an elevation of a leading minor-flap plow based at least inpart on the difference between the obtained measurement and the standardmeasurement.
 16. The method of claim 1, wherein operating thecase-handling tool responsive to the executed programming comprises atleast one of: adjusting a degree to which jaws of a major flap kickerare opened based at least in part on the difference between the obtainedmeasurement and the standard measurement; adjusting a timing at whichthe jaws of the major flap kicker are closed based at least in part onthe difference between the obtained measurement and the standardmeasurement; or adjusting an elevation of the major flap kicker based atleast in part on the difference between the obtained measurement and thestandard measurement.
 17. The method of claim 1, wherein operating thecase-handling tool responsive to the executed programming comprises:adjusting an elevation of a tape-head or a glue-head based at least inpart on the difference between the obtained measurement and the standardmeasurement.
 18. The method of claim 1, wherein operating thecase-handling tool responsive to the executed programming comprises:adjusting a location of a flight lug on a conveyor based at least inpart on the difference between the obtained measurement and the standardmeasurement.
 19. The method of claim 1, wherein operating thecase-handling tool responsive to the executed programming comprises:adjusting operation of a minor flap kicker based at least in part on thedifference between the obtained measurement and the standardmeasurement, wherein the adjustment comprises one or more of: adjustinga separation between elements of the minor flap kicker; adjusting atiming at which the minor flap kicker operates; and adjusting anelevation of the minor flap kicker.
 20. The method of claim 1, whereinoperating the case-handling tool responsive to the executed programmingcomprises: adjusting a size of a mandrel based at least in part on thedifference between the obtained measurement and the standardmeasurement.
 21. The method of claim 1, wherein operating thecase-handling tool responsive to the executed programming comprises:adjusting at least one flap spreader based at least in part on thedifference between the obtained measurement and the standardmeasurement.
 22. A method for case-handling, comprising: obtaining ameasurement of an aspect of a knocked-down case; determining a standardmeasurement of the aspect; determining a difference between the obtainedmeasurement and the standard measurement of the aspect, whereindetermining the difference comprises determining distances between atleast one pair of case features, wherein the case features, comprise: anedge of the knocked-down case; a score of the knocked-down case; and afold of the knocked-down case; executing programming, wherein theprogramming is based at least in part on the determined difference, andwherein the programming sends control signals to a case-handling tool;and operating the case-handling tool according to the control signals.23. A method for case-handling, comprising: obtaining a measurement ofan aspect of a case in a stage of assembly; determining a differencebetween the obtained measurement of the case in the stage of assemblyand a standard measurement; executing programming that sends controlsignals to a case-handling tool, wherein the control signals are basedon inputs comprising: the difference determined between the obtainedmeasurement and the standard measurement; and the stage of assembly ofthe case; and operating the case-handling tool by the execution of theprogramming.
 24. The method of claim 23, wherein the measurement of theaspect is a distance between two case elements, the two case elementsselected from among case elements comprising: an edge of the case; ascore of the case; and a fold of the case.
 25. The method of claim 23,wherein the method comprises operating a plurality of tools to perform arespective plurality of functions, comprising: rotating to orientcorrugations of the case; cutting to make one or more edges of the case;scoring the case to create one or more fold-lines of the case; foldingthe case along the one or more fold-lines created by the scoring; andtaping together two edges of the case.
 26. The method of claim 23,wherein the method results in a completed knocked-down case, and whereinthe method additionally comprises: printing indicia on the completedknocked-down case, wherein the indicia comprise one or moremeasurements.
 27. A method to inspect and assemble a knocked-down case,comprising: obtaining a measurement of an aspect of the knocked-downcase; determining a difference between the obtained measurement and astandard measurement, wherein determining the difference between theobtained measurement and the standard measurement comprises determininga difference between the obtained measurement and at least one end of arange of standard measurements; executing programming of a case-handlingtool, wherein the executed programming is based at least in part on thedetermined difference; and operating the case-handling tool responsiveto the executed programming to at least partially erect the knocked-downcase into an erected case.
 28. A method to inspect and assemble aknocked-down case, comprising: obtaining a measurement of an aspect ofthe knocked-down case; determining a difference between the obtainedmeasurement and a standard measurement; selecting a case-handling toolfrom among a plurality of case-handling tools based at least in part onwhether programming of the case-handling tool will result in an erectedcase being within a specification of the erected case; executing theprogramming of the case-handling tool, wherein the executed programmingis based at least in part on the determined difference; and operatingthe case-handling tool responsive to the executed programming to atleast partially erect the knocked-down case into the erected case.
 29. Amethod to inspect and assemble a knocked-down case, comprising:obtaining a measurement of an aspect of the knocked-down case;determining a difference between the obtained measurement and a standardmeasurement, wherein the determined difference between the obtainedmeasurement and the standard measurement is used to select acase-handling tool from among a plurality of case-handling tools and isused to determine changes to at least one of a program, variables, anddata used by the program of the selected case-handling tool; executingthe program of the case-handling tool, wherein the executed program isbased at least in part on the determined difference; and operating thecase-handling tool responsive to the executed program to at leastpartially erect the knocked-down case into an erected case.
 30. A methodto inspect and assemble a knocked-down case, comprising: obtaining ameasurement of an aspect of the knocked-down case; determining adifference between the obtained measurement and a standard measurement;executing programming of a case-handling tool, wherein the executedprogramming is based at least in part on the determined difference; andoperating the case-handling tool responsive to the executed programmingto at least partially erect the knocked-down case into an erected case,wherein operating the case-handling tool responsive to the executedprogramming comprises operating a robotic arm and end-of-arm tool toplace the erected case at a location that is based at least in part onthe difference between the obtained measurement and the standardmeasurement.
 31. A method to inspect and assemble a knocked-down case,comprising: obtaining a measurement of an aspect of the knocked-downcase; determining a difference between the obtained measurement and astandard measurement; executing programming of a case-handling tool,wherein the executed programming is based at least in part on thedetermined difference; and operating the case-handling tool responsiveto the executed programming to at least partially erect the knocked-downcase into an erected case, wherein operating the case-handling toolresponsive to the executed programming comprises adjusting an elevationof a leading minor-flap plow based at least in part on the differencebetween the obtained measurement and the standard measurement.
 32. Amethod to inspect and assemble a knocked-down case, comprising:obtaining a measurement of an aspect of the knocked-down case;determining a difference between the obtained measurement and a standardmeasurement; executing programming of a case-handling tool, wherein theexecuted programming is based at least in part on the determineddifference; and operating the case-handling tool responsive to theexecuted programming to at least partially erect the knocked-down caseinto an erected case, wherein operating the case-handling toolresponsive to the executed programming comprises at least one of:adjusting a degree to which jaws of a major flap kicker are opened basedat least in part on the difference between the obtained measurement andthe standard measurement; adjusting a timing at which the jaws of themajor flap kicker are closed based at least in part on the differencebetween the obtained measurement and the standard measurement; oradjusting an elevation of the major flap kicker based at least in parton the difference between the obtained measurement and the standardmeasurement.
 33. A method to inspect and assemble a knocked-down case,comprising: obtaining a measurement of an aspect of the knocked-downcase; determining a difference between the obtained measurement and astandard measurement; executing programming of a case-handling tool,wherein the executed programming is based at least in part on thedetermined difference; and operating the case-handling tool responsiveto the executed programming to at least partially erect the knocked-downcase into an erected case, wherein operating the case-handling toolresponsive to the executed programming comprises adjusting an elevationof a tape-head or a glue-head based at least in part on the differencebetween the obtained measurement and the standard measurement.
 34. Amethod to inspect and assemble a knocked-down case, comprising:obtaining a measurement of an aspect of the knocked-down case;determining a difference between the obtained measurement and a standardmeasurement; executing programming of a case-handling tool, wherein theexecuted programming is based at least in part on the determineddifference; and operating the case-handling tool responsive to theexecuted programming to at least partially erect the knocked-down caseinto an erected case, wherein operating the case-handling toolresponsive to the executed programming comprises adjusting a location ofa flight lug on a conveyor based at least in part on the differencebetween the obtained measurement and the standard measurement.
 35. Amethod to inspect and assemble a knocked-down case, comprising:obtaining a measurement of an aspect of the knocked-down case;determining a difference between the obtained measurement and a standardmeasurement; executing programming of a case-handling tool, wherein theexecuted programming is based at least in part on the determineddifference; and operating the case-handling tool responsive to theexecuted programming to at least partially erect the knocked-down caseinto an erected case, wherein operating the case-handling toolresponsive to the executed programming comprises: adjusting operation ofa minor flap kicker based at least in part on the difference between theobtained measurement and the standard measurement, wherein theadjustment comprises one or more of: adjusting a separation betweenelements of the minor flap kicker; adjusting a timing at which the minorflap kicker operates; and adjusting an elevation of the minor flapkicker.
 36. A method to inspect and assemble a knocked-down case,comprising: obtaining a measurement of an aspect of the knocked-downcase; determining a difference between the obtained measurement and astandard measurement; executing programming of a case-handling tool,wherein the executed programming is based at least in part on thedetermined difference; and operating the case-handling tool responsiveto the executed programming to at least partially erect the knocked-downcase into an erected case, wherein operating the case-handling toolresponsive to the executed programming comprises adjusting a size of amandrel based at least in part on the difference between the obtainedmeasurement and the standard measurement.
 37. A method to inspect andassemble a knocked-down case, comprising: obtaining a measurement of anaspect of the knocked-down case; determining a difference between theobtained measurement and a standard measurement; executing programmingof a case-handling tool, wherein the executed programming is based atleast in part on the determined difference; and operating thecase-handling tool responsive to the executed programming to at leastpartially erect the knocked-down case into an erected case, whereinoperating the case-handling tool responsive to the executed programmingcomprises: adjusting at least one flap spreader based at least in parton the difference between the obtained measurement and the standardmeasurement.